Title Page

TASHKENT TURIN POLYTECHNICAL UNIVERSITY

BACHELOR OF SCIENCE ON
Information Technology and ACS

Final project work on

Maintaining Sustainable Energy in Automated Systems for
Large-Scale Production Efficiency

Candidate
Sardor Kholmatov

Signature:

Supervisor

Signature:

TTPU
2024
 Committee Membership Page

Abstract

Maintaining Sustainable Energy in Automated Systems for Large-Scale

Production Efficiency

Sardor Xolmatov Sobirjon o’g’li,

Tashkent Turin Polytechnical University, 2024

This thesis provides a comprehensive exploration of the essential knowledge, skills, and
practices required for power engineers, focusing on both theoretical foundations and practical
applications within industrial settings. Beginning with a general introduction to the enterprise, it
outlines the educational training necessary for power engineers, covering fundamental
knowledge and essential technical skills. A key aspect of the thesis is the detailed inspection of
all technical equipment, ensuring that engineers are proficient in evaluating and maintaining
operational standards.

Safety is paramount in electrical engineering; thus, the thesis emphasizes the importance
of adhering to electrical safety rules and production safety techniques. It also outlines necessary
precautions and preparatory measures that must be in place to ensure a safe working
environment.

The thesis delves into equipment maintenance procedures, highlighting preventive

maintenance and strategic planning for conveyor line inspections. It underscores the significance
of maintaining automatic control systems, exploring the automation of energy systems and
processes, and optimal distribution of energy resources to enhance efficiency.

A significant portion of the thesis is dedicated to the maintenance of performance levels

in automation systems, focusing on power load management, peak power control, and the
analysis of errors in system automation. It provides an in-depth look at electrical control boxes,
detailing the function and maintenance of starters, circuit breakers, and protection systems
against over-voltage and overload.

Attention is given to the key components of conveyor production machinery, including

the principles of electric motor operations and the integration of specialized tools for component
modifications. The role of lighting control and the utilization of various sensors for equipment
protection within manufacturing systems are also examined.

The monitoring of energy processes is crucial for maintaining efficient operations, and
this thesis outlines effective strategies for continuous monitoring and management. Additionally,
it discusses the optimal use of production downtime, emphasizing efficient time utilization to
ensure continuous improvement and productivity.

TTPU 2024
 Overall, this thesis serves as a vital resource for power engineers, providing them with
the knowledge and tools necessary to excel in their roles, ensure safety, and maintain high
standards of operational efficiency in industrial environments.

TTPU 2024
 Table of Contents

1.0. General introduction about the Enterprise

1.1. General Educational Training

1.2. Basic Knowledge and Skills for Power Engineer

1.3. General Inspection of All Technical Equipment

2.0. Necessary Precautions and Preparatory Measures

2.1. Rules and Standards of Electrical Safety

2.2 Compliance with Production Safety Techniques

3.0. Equipment Maintenance Procedures

3.1. Preventive Maintenance

3.2. Planning Before Conveyor Line Inspections

4.0. Familiarization with Automatic Control Systems

4.1. Automation of Energy Systems and Processes

4.2. Methods for Optimal Distribution of Energy Resources

5.0. Maintenance of Performance Levels in Automation Systems

5.1. Power Load Management and Peak Power Control

5.2. Analysis of Errors in System Automation

6.0. Familiarization with Electrical Control Box

6.1. Starters and Circuit Breakers

6.2. Phase Line Overvoltage Protection

6.3. Installation of Overload Protection for Equipment

6.4. Cable Sizing for Overload Protections

TTPU 2024
7.0. Maintenance of Key Components in Conveyor Production Machinery

7.1. Principles of Electric Motor Operations

7.2. Incandescent Lamps and Their Connections

7.3. Specialized Tools for Modifying Unique Components

8.0. Fundamental Components of Manufacturing Systems

8.1. Establishing Lighting Control for Enterprises

8.2. Utilizing various Sensors for Comprehensive Equipment Protection

9. Monitoring of All Energy Processes

10. Efficient Time Utilization During Production Downtime

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 List of Figures

Figure 1 Personal Protective Equipment.....................................................................................6

TTPU 2024
Figure 2 Electric Engineer Tools..................................................................................................7

Figure 3 Industrial Electrical Equipment.................................................................................19

Figure 4 Various Industrial Cable Types..................................................................................23

List of Tables

Table 1 Cable Selection Chart....................................................................................................36

TTPU 1 2024
1.0. General Introduction about the Enterprise

The enterprise dedicated to recycling paper and producing boxes plays a vital role in

promoting sustainability and reducing environmental impact. This type of enterprise focuses on

converting waste paper into new, usable paper products and packaging materials, which helps in

conserving natural resources and minimizing landfill waste. The operation typically involves

several key facilities:

 Paper Recycling Plant: This facility is responsible for the collection, sorting, and initial
processing of waste paper. It includes equipment for shredding, washing, and deinking
the paper to prepare it for further processing.
 Pulping Equipment: Pulping is a crucial step where the sorted waste paper is
transformed into pulp. This involves mechanical and chemical processes to break down
the paper fibers and remove contaminants.
 Box Manufacturing Plant: This plant uses the pulp to create new paper products and
cardboard. It houses machinery such as paper machines, corrugators, die-cutters, and
printers to produce various types of boxes and packaging materials.
 Power Systems: The operation of these facilities relies heavily on a robust electrical
infrastructure. This includes the generation, distribution, and management of electrical
power to ensure smooth and efficient operations.
 Sustainability Initiatives: The enterprise often employs energy-efficient technologies
to reduce its carbon footprint and enhance sustainability.

Overall, the enterprise not only meets its production goals but also contributes

significantly to environmental conservation and resource management.

1.1. General Educational Training

TTPU 2 2024
 To become a power and electrical engineer in the paper recycling and box manufacturing

industry, a structured educational pathway is essential. This typically begins with a Bachelor’s

Degree in Electrical Engineering, which provides foundational knowledge in key areas such as

control systems and power electronics. The educational journey includes:

 Specialized Courses: Students can take elective courses that focus on industrial

automation, process control, aligning their education with industry needs.

 Laboratory and Practical Work: Hands-on training through laboratory sessions allows

students to apply theoretical knowledge to real-world scenarios. This includes working

with electrical machines, power systems, and automation systems.

 Internship: Gaining practical experience through internship programs is crucial. These

opportunities provide exposure to actual industrial settings and allow students to learn

directly from professionals.

 Advanced Degrees: For further specialization, pursuing a master’s or doctoral degree

can be beneficial. Advanced studies might focus on areas such as sustainable energy

systems, advanced control techniques, or industrial process optimization.

Key learning outcomes from this educational pathway include technical proficiency,

problem-solving skills, practical experience, effective communication, and project management

abilities, all of which are essential for a successful career in the industry.

1.2. Basic Knowledge and Skills for Power Engineer

TTPU 3 2024
 Power engineers in the paper recycling and box manufacturing industry require a solid

foundation in several core areas:

 Electrical Systems and Machinery: Understanding the principles of operation and

maintenance of electrical machinery used in the industry, including motors, drives,
generators, and transformers.
 Power Distribution and Management: Knowledge of how electrical power is
generated, transmitted, and distributed within industrial settings. This includes load
management, power quality, and ensuring a reliable power supply.
 Industrial Automation and Control: Proficiency in automation systems such as PLCs
(Programmable Logic Controllers), SCADA (Supervisory Control and Data Acquisition),
and DCS (Distributed Control Systems). These systems are crucial for monitoring and
controlling manufacturing processes. Unfortunately our production setup only automated
with the "PLC." Its capabilities are sufficient for our immediate requirements, and we
plan to incorporate further enhancements as needed in the future.
 Energy Management and Efficiency: Skills in optimizing energy usage, trying to
integrate renewable energy sources, and implementing energy-efficient technologies.
 Safety Standards: Familiarity with industrial safety standards and regulations to
maintain a safe working environment and ensure compliance with industry norms.

In addition to technical knowledge, power engineers must possess strong analytical skills

to troubleshoot and solve complex problems, as well as communication skills to effectively

convey technical information to various stakeholders.

1.3. General Inspection of All Technical Equipment

TTPU 4 2024
 Regular inspection and maintenance of technical equipment are critical to the smooth

operation of a paper recycling and box manufacturing enterprise. Key inspection procedures

include:

 Visual Inspection: Regularly checking all electrical and mechanical components for

signs of wear, damage, or corrosion. This helps in identifying potential issues before they

escalate.

 Thermal Imaging: Using infrared cameras to detect overheating in electrical

components, motors, and control panels, which can indicate potential failures.

 Electrical Testing: Performing tests such as insulation resistance, grounding system

checks, and continuity tests to ensure the integrity and safety of electrical systems.

 Functional Testing: Verifying that all machinery and control systems operate correctly

under normal and fault conditions. This includes testing protection relays, control

systems, and backup power supplies.

 Preventive Maintenance: Conducting regular maintenance activities, such as

lubrication, cleaning, and replacement of worn-out parts, to prevent unexpected

breakdowns.

Proper documentation and reporting are also essential. This includes maintaining

maintenance logs, inspection reports, and safety records to ensure traceability and compliance

with regulatory requirements. Regular energy audits can help identify opportunities for

improving energy efficiency and integrating renewable energy sources, further enhancing the

sustainability of the enterprise.

2.0. Necessary Precautions and Preparatory Measures

TTPU 5 2024
 To ensure safety and efficiency in a paper recycling and box manufacturing factory,

several precautions and preparatory measures are crucial:

 Risk Assessment: Conducting thorough evaluations to identify potential hazards such as

electrical shocks, fire risks, chemical exposure, and mechanical failures. This proactive
approach helps mitigate risks before they become issues.
 Emergency Preparedness: Developing and implement detailed emergency response
plans, including fire drills, evacuation procedures, and first-aid training. Ensure that first-
aid kits and emergency medical support are readily accessible throughout the facility.
 Personal Protective Equipment (PPE): Supplying appropriate PPE such as hard hats,
safety glasses, gloves, hearing protection, and insulated footwear you can see in Figure 1.
Enforce the consistent use of PPE to protect engineers from various hazards during
inspections of machines.

Figure 1: Personal Protective Equipment

Electrical Engineer Equipment and Tools

TTPU 6 2024
 Equipping electrical engineers with essential tools is crucial for maintaining safety and
efficiency in a paper recycling and box manufacturing factory.

 Multimeters: For measuring voltage, current, and resistance.

 Insulated Hand Tools: Including screwdrivers, pliers, and wire strippers for safe
handling of live wires. (see
Figure 2)

Figure 2: Electric Engineer

Tools

 Wire Cutters and Strippers: For proper connections and repairs.

 Cable Testers: To ensure the integrity of cables and wiring.
 Voltage Testers: To check for the presence of voltage.
 Digital Calipers: For precision measurements.
 Circuit Breaker Finders: To identify circuit breakers.
 Headlamps and Flashlights: For illumination in dark areas.
 Portable Tool Kits: With various hand tools.

Implementing these necessary precautions and preparatory measures ensures a safer

working environment and helps prevent accidents. Prioritizing risk assessment, emergency
preparedness, PPE, and engineers tools significantly enhances safety and efficiency.

2.1. Rules and Standards of Electrical Safety

TTPU 7 2024
 Adhering to strict electrical safety standards is essential in the factory environment:

 Regulatory Compliance: Ensuring that all electrical installations and equipment meet
the standards set by regulatory bodies such as the National Electrical Code (NEC),
International Electrotechnical Commission (IEC), and Occupational Safety and Health
Administration (OSHA).
 Lockout/Tagout Procedures: Implementing and rigorously follow lockout/tagout
(LOTO) procedures to ensure that machinery is safely shut off and cannot be restarted
during maintenance or repair work, preventing accidental energizing.
 Grounding and Bonding: Properly ground and bond all electrical systems to reduce the
risk of electrical shocks and ensure safe operation of equipment.
 Over-current Protection: Using appropriate over-current protection devices, including
fuses and circuit breakers, to prevent overloads and short circuits that could cause fires or
damage equipment.
 Insulation and Enclosures: Ensuring that all electrical wiring and components are
adequately insulated and enclosed to prevent accidental contact and reduce shock risk.
 Regular Inspections: Conducting regular inspections of electrical systems to identify
potential hazards such as frayed wires, loose connections, and malfunctioning equipment.
Take immediate corrective action as needed.

By adhering to these stringent electrical safety rules and standards, a paper recycling and
box manufacturing factory can protect its personnel and equipment from electrical hazards. This
ensures a safer workplace, minimizing the risk of electrical accidents and ensuring smooth
operations.

2.2. Compliance with Production Safety Techniques

TTPU 8 2024
 Maintaining compliance with production safety techniques to a safe and efficient factory:

 Safety Audits and Inspections: Conducting regular safety audits and inspections to
ensure compliance with safety regulations and internal policies. These audits help
identify potential hazards and areas for safety improvements.
 Standard Operating Procedures (SOPs): Developing and enforce SOPs for all
production processes. Clearly defined procedures help employees perform tasks safely
and efficiently, reducing the risk of accidents.
 Machine Safety Guards: Ensuring that all machinery is equipped with appropriate
safety guards and emergency stop buttons. Safety guards provide physical barriers, and
emergency stops allow quick shutdown in case of an emergency.
 Hazard Communication: Implementing a hazard communication program to inform
employees about the dangers of chemicals and materials they work with. Proper labeling
of hazardous substances and availability of Material Safety Data Sheets (MSDS) are
essential.
 Incident Reporting and Investigation: Establishing a system for reporting and
investigating accidents, near misses, and unsafe conditions. Analyzing these incidents
helps identify root causes and implement measures to prevent recurrence.
 Continuous Improvement: Fostering a culture of continuous improvement in safety
practices. Regularly review and update safety policies, encourage employee feedback,
and stay informed about the latest safety regulations and technologies.

Compliance with these production safety techniques fosters a culture of safety,

preventing workplace accidents and ensuring efficient operations. Regular safety audits, clear
SOPs, machine safety guards, hazard communication, incident reporting, continuous
improvement, and employee involvement are key elements in maintaining a safe and productive
factory environment.

3.0. Equipment Maintenance Procedures

TTPU 9 2024
 Proper maintenance procedures are essential for ensuring the longevity and optimal
performance of equipment in a paper recycling and box manufacturing factory. Effective
maintenance minimizes downtime, reduces repair costs, and ensures safety. Key components
include developing a maintenance schedule, training personnel, using maintenance management
systems, maintaining detailed procedures, conducting regular audits, managing inventory, and
collaborating with equipment manufacturers.

3.1. Preventive Maintenance

Preventive maintenance aims to minimize equipment failures and extend machinery

lifespan. This involves:

 Scheduled Inspections: Regularly scheduled inspections to identify signs of wear and

potential issues before they lead to failures.
 Routine Servicing: Tasks such as lubrication, filter replacements, and cleaning to keep
machinery running smoothly and efficiently.
 Component Replacement: Proactively replacing parts prone to wear, such as belts and
bearings, before they fail to avoid unexpected breakdowns.
 Calibration and Testing: Regular calibration of sensors and control systems to ensure
equipment operates within specified parameters.
 Record Keeping: Maintaining detailed records of all preventive maintenance activities,
inspections, and component replacements to track equipment history and plan future
maintenance.

Implementing preventive maintenance reduces the risk of unexpected failures, enhances

operational efficiency, and extends equipment lifespan.

3.2. Planning Before Conveyor Line Inspections

TTPU 10 2024
 Proper planning before conducting conveyor line inspections ensures thorough and

efficient evaluations, minimizing downtime and maintaining productivity. This involves:

 Inspection Scheduling: Plan inspections during non-peak hours or scheduled downtime

to minimize disruption to production.
 Preparation of Tools and Equipment: Ensure all necessary tools and equipment for the
inspection are prepared in advance, including inspection mirrors, wrenches, and
lubricants.
 Checklists: Develop detailed inspection checklists covering all aspects of the conveyor
line, including belts, rollers, motors, and safety guards, to ensure thorough inspections.
 Safety Precautions: Implement safety measures such as de-energizing and locking out
the conveyor line, wearing appropriate PPE, and ensuring all safety guards are in place.
 Documentation: Record all findings during the inspection, including issues identified
and corrective actions taken, to provide a reference for future inspections and
maintenance planning.
 Follow-up Actions: Plan and schedule any necessary repairs or maintenance tasks
identified during the inspection promptly to prevent minor issues from escalating into
major problems.

Effective planning before conveyor line inspections helps maintain operational efficiency

and reliability, reducing the risk of unexpected breakdowns and production delays.

By adhering to these equipment maintenance procedures, including preventive

maintenance and thorough planning before conveyor line inspections, the factory can ensure the

smooth and efficient operation of its machinery, enhancing productivity and safety.

4.0. Familiarization with Automatic Control Systems

TTPU 11 2024
 Automatic control systems are integral to modern paper recycling and box manufacturing

factories. These systems enhance efficiency, ensure consistent quality, and reduce manual labor

by automating various processes. Familiarization with these systems involves understanding

their components, functions, and benefits.

 Components of Control Systems: Key components include sensors, actuators,

controllers, and Human-Machine Interfaces (HMIs). Sensors collect data, actuators

perform actions based on controller signals, controllers process data to make decisions,

and HMIs allow human operators to interact with the system.

 Functions and Benefits: Automatic control systems monitor and control production

processes, maintaining optimal conditions and improving productivity. Benefits include

increased precision, reduced errors, and enhanced safety.

 Training and Skills: Operators and engineers must be trained to use and maintain these

systems. Skills in programming, troubleshooting, and data analysis are essential for

effective system management.

Familiarizing with automatic control systems is essential for modernizing and optimizing

operations in a paper recycling and box manufacturing factory. Understanding these systems'

components, functions, and benefits, as well as ensuring proper training for personnel, allows the

factory to achieve increased efficiency, consistent quality, and enhanced safety.

4.1. Automation of Energy Systems and Processes

TTPU 12 2024
 Automation in energy systems and processes is crucial for improving efficiency and

reducing operational costs in a paper recycling and box manufacturing factory.

 Energy Management Systems (EMS): EMS monitor and control energy consumption,

ensuring efficient use of resources. These systems can automatically adjust energy use

based on real-time data and predefined parameters.

 Automated Process Control: Automation in processes such as pulping, drying, and

cutting ensures consistent quality and reduces waste. Automated control systems can

adjust variables like temperature, pressure, and speed to optimize process efficiency.

 Smart Grids and Renewable Integration: Smart grids enable efficient distribution and

use of electricity. Automation helps balance energy supply and demand, reducing

reliance on non-renewable sources and optimizing the use of available energy resources.

 Predictive Maintenance: Using automation for predictive maintenance involves

monitoring equipment condition and predicting failures before they occur. This reduces

downtime and extends the lifespan of machinery.

Automating energy systems and processes significantly boosts efficiency and reduces

operational costs. By implementing energy management systems, automated process control,

smart grids, and predictive maintenance, the factory can ensure optimal energy use, reduce

waste, and maintain high productivity levels.

4.2. Methods for Optimal Distribution of Energy Resources

TTPU 13 2024
 Optimal distribution of energy resources ensures efficient and sustainable operations in a

paper recycling and box manufacturing factory.

 Energy Audits: Conduct regular energy audits to identify areas of high energy

consumption and potential savings. Audits help prioritize energy efficiency projects and

track improvements over time.

 Load Management: Implement load management strategies to balance energy use and

reduce peak demand charges. This can involve scheduling high-energy-consuming

processes during off-peak hours.

 Energy Storage Systems: Use energy storage systems, such as batteries, to store excess

energy during low-demand periods and supply it during peak demand. This helps in

stabilizing energy supply and reducing costs.

 Real-Time Monitoring: Deploy real-time energy monitoring systems to track energy

usage continuously. These systems provide data for making informed decisions about

energy use and identifying inefficiencies.

 Using Power-Efficient Machineries: Invest in power-efficient machinery and

equipment that consume less energy while maintaining high performance. This reduces

overall energy consumption and operational costs.

Optimal distribution of energy resources is vital for sustainable and cost-effective

operations. Regular energy audits, load management, energy storage systems, real-time
monitoring, and the use of power-efficient machinery are effective strategies. These methods
help balance energy use, reduce costs, and minimize environmental impact, ensuring efficient
and sustainable energy management.

5.0. Maintenance of Performance Levels in Systems

TTPU 14 2024
 Maintaining performance levels in systems (Automated systems) is crucial for

ensuring smooth and efficient operations in a paper recycling and box manufacturing factory.

This involves regular maintenance, performance monitoring, troubleshooting, and optimization

of automated processes.

 Regular Maintenance Procedures: Implementing routine maintenance schedules to

upkeep automation systems and prevent unexpected breakdowns.
 Performance Monitoring and Analysis: Continuously monitoring system performance
metrics to identify deviations and areas for improvement.
 Troubleshooting and Issue Resolution: Developing procedures for diagnosing and
resolving issues promptly to minimize downtime and maintain productivity.
 Optimization of Automated Processes: Fine-tune automation settings and parameters to
maximize efficiency and quality while minimizing waste.
 Integration with Maintenance Management Systems: Integrating automation systems
with maintenance management systems to streamline maintenance activities and improve
overall system reliability.
 Training and Skill Development: Providing training and skill development
opportunities for personnel to ensure effective operation and maintenance of automation
systems.

Maintenance of performance levels in automation systems ensures smooth and efficient

operations in a paper recycling and box manufacturing factory.

5.1. Power Load Management and Peak Power Control

TTPU 15 2024
 Effective power load management and peak power control are crucial for optimizing

energy consumption and minimizing costs in a paper recycling and box manufacturing factory.

 Load Monitoring and Analysis: Continuously monitoring energy consumption patterns

to identify opportunities for load optimization.

 Load Shifting Strategies: Implementing strategies to shift energy-intensive processes to

off-peak hours to reduce peak demand.

 Peak Power Control Measures: Deploying measures such as demand response

programs or energy storage systems to manage peak power usage.

 Automation of Load Management: Utilizing automation systems to optimize energy

usage and respond dynamically to changing demand conditions.

 Economic and Operational Impacts of Factory Equipment: Incorporating efficient

and long-lasting factory equipment can reduce reliance on traditional energy sources and

operate smoothly over an extended period. However, this may involve higher initial

costs.

 Continuous Improvement: Regularly evaluate and refine power load management

strategies to adapt to changing production demands and energy market conditions.

Effective power load management and peak power control optimize energy consumption

and minimize costs in the factory.

TTPU 16 2024
5.2. Analysis of Errors in System Automation

Analyzing errors in system automation is essential for identifying and addressing

issues that may compromise production efficiency and product quality in a paper recycling and

box manufacturing factory.

 Error Detection Systems: Implement automated error detection mechanisms to identify

anomalies and deviations from expected system behavior.

 Root Cause Analysis: Conduct in-depth investigations to determine the underlying

causes of automation errors, including equipment malfunctions, software bugs, or human

errors.

 Corrective Action Planning: Develop strategies for implementing corrective actions to

address identified errors and prevent recurrence.

 Continuous Monitoring and Improvement: Establish protocols for ongoing monitoring

of system performance and the effectiveness of error mitigation measures.

 Training and Skill Development: Provide training programs to equip personnel with the

knowledge and skills required to troubleshoot and resolve automation errors effectively.

 Documentation and Knowledge Sharing: Maintain comprehensive records of

automation errors and their resolutions to facilitate knowledge sharing and continuous

improvement efforts.

Effective analysis of errors in system automation helps minimize production disruptions,

enhance system reliability, and improve overall operational efficiency in a paper recycling and

box manufacturing factory.

TTPU 17 2024
6.0. Familiarization with Electrical Control Box

Familiarizing with the electrical control box is vital for ensuring safe and effective

operation of machinery in a paper recycling and box manufacturing factory. This includes

understanding the components, functions, and proper handling of the control box to maintain

operational efficiency and safety standards.

 Understanding Components: The electrical control box typically houses circuit

breakers, fuses, relays, timers, and various control switches. Knowing the role and

location of each component is crucial for troubleshooting and maintenance. (see Figure 3)

 Operational Functions: Learn how the control box manages and distributes electrical

power to various parts of the machinery. This includes starting and stopping motors,

regulating voltage and current, and protecting circuits from overloads and short circuits.

 Safety Protocols: Adhere to safety protocols such as ensuring the control box is properly

grounded, regularly inspecting for signs of wear or damage, and keeping the area around

the box clean and dry.

 Hands-On Training: Engage in hands-on training to gain practical experience with the

control box, including how to safely open and close the box, replace fuses or reset

breakers, and interpret control box diagrams and labels.

Familiarizing with the electrical control box is essential for maintaining the operational

efficiency and safety of the machinery in a paper recycling and box manufacturing factory.

TTPU 18 2024
 Figure 3: Industrial Electrical Equipment

TTPU 19 2024
6.1. Starters and Circuit Breakers

Starters and circuit breakers are critical components in managing the electrical loads

and protecting equipment in a paper recycling and box manufacturing factory.

 Types of Starters: Understand the various types of starters (e.g., direct-on-line, star-

delta, soft starters) and their applications in starting and controlling motors.

 Circuit Breaker Functions: Learn the function of circuit breakers in interrupting

excessive current flow to protect electrical circuits from damage.

 Selection Criteria: Know the criteria for selecting appropriate starters and circuit

breakers based on the load requirements and safety standards.

 Installation Procedures: Follow proper installation procedures to ensure starters and

circuit breakers are correctly set up and connected.

 Maintenance Practices: Implement regular maintenance practices to ensure the reliable

operation of starters and circuit breakers, including checking for signs of wear or damage.

 Testing and Calibration: Perform routine testing and calibration to verify that starters

and circuit breakers function correctly and provide adequate protection.

Starters and circuit breakers play a crucial role in managing electrical loads and

safeguarding equipment, ensuring efficient and safe operations in the factory.

TTPU 20 2024
6.2. Phase Line Over-voltage Protection

Phase line over-voltage protection is essential for preventing damage to electrical

equipment due to sudden voltage spikes in a paper recycling and box manufacturing factory.

 Causes of Over-voltage: Understand common causes of over-voltage, such as lightning

strikes, switching surges, and equipment faults.

 Protection Devices: Learn about various over-voltage protection devices, including

surge protectors, voltage clamping devices, and transient voltage suppressors.

 Installation Guidelines: Follow best practices for installing over-voltage protection

devices to ensure effective protection of phase lines.

 System Integration: Integrate over-voltage protection with existing electrical systems to

provide comprehensive protection across all phases.

 Regular Testing: Conduct regular testing of over-voltage protection devices to ensure

they function correctly and provide adequate protection.

 Documentation and Monitoring: Maintain documentation of installed over-voltage

protection devices and monitor their performance over time.

Effective phase line over-voltage protection is vital for safeguarding electrical equipment

and maintaining the reliability of electrical systems in the factory.

TTPU 21 2024
6.3. Installation of Overload Protection for Equipment

Installing overload protection for equipment is critical to prevent damage from

excessive current flow, ensuring the longevity and reliability of machinery in a paper recycling

and box manufacturing factory.

 Types of Overload Protection: Understand different types of overload protection

devices, such as thermal overload relays, magnetic relays, and electronic overload

protectors.

 Selection and Sizing: Select and size overload protection devices appropriately based on

the equipment specifications and load requirements.

 Appropriate Cable Sizing for Manufacturing Equipment: For detailed information,

please refer to the cable sizing guidelines provided at the end of the chapter.

 Calibration and Setting: Calibrate and set overload protection devices according to the

equipment manufacturer's recommendations to ensure optimal protection.

 Regular Inspection and Maintenance: Conduct regular inspections and maintenance of

overload protection devices to ensure they remain effective and reliable.

 Troubleshooting and Adjustment: Develop skills for troubleshooting and adjusting

overload protection devices to address any issues that arise during operation.

Installing overload protection for equipment is essential for preventing damage due to

excessive current, thereby enhancing the safety and reliability of machinery in the factory.

TTPU 22 2024
6.4. Cable Sizing for Overload Protections

Figure 4: Various Industrial Cable Types

 Cable Types: Different types of cables are used for various applications based on their
characteristics and suitability: (You can see some data from Figure 4 and Table 1)
o PVC Insulated Cables: Commonly used for general electrical installations. They
offer good insulation properties and are suitable for indoor use.
o XLPE Cables (Cross-Linked Polyethylene): Known for their high-temperature
resistance and durability, making them suitable for both indoor and outdoor
installations.
o Armored Cables: Provide additional protection against mechanical damage.
They are ideal for underground or industrial applications where the cable might
be exposed to harsh conditions.
o Flexible Cables: Used for applications where cables need to bend or flex, such as
connections to moving machinery.
o Shielded Cables: Contain an additional shielding layer to protect against
electromagnetic interference, suitable for sensitive electronic equipment.

TTPU 23 2024
 Proper cable sizing for overload protection is crucial to ensure the safe and efficient

operation of electrical systems in a paper recycling and box manufacturing factory. The correct

cable size prevents overheating, reduces energy losses, and protects against potential fire

hazards. Selecting the appropriate cable involves considering the electrical load, the length of the

cable run, ambient temperature, and installation conditions.

 Determining Electrical Load: Calculate the total electrical load that the cable will carry.

This includes considering the current drawn by all connected equipment and any potential

future expansions. The load calculation helps determine the minimum current-carrying

capacity required for the cable.

 Ambient Temperature and Installation Conditions: Consider the ambient temperature

and installation conditions, as these factors affect the current-carrying capacity of the

cable. For example, cables installed in hot environments or in conduit bundles require

derating to account for reduced cooling.

 Compliance with Standards: Adhere to relevant electrical standards and regulations

when selecting and installing cables. This ensures safety and compliance with legal

requirements.

 Overload Protection Devices: Integrate overload protection devices such as circuit

breakers or fuses with the selected cables. These devices protect the cables from carrying

excessive current, which can cause overheating and potential fire hazards.

Proper cable sizing for overload protection ensures the safety and efficiency of electrical

systems in a paper recycling and box manufacturing factory, preventing potential hazards and

ensuring reliable operation of equipment.

TTPU 24 2024
7.0. Maintenance of Key Components in Conveyor

Machinery

Maintaining key components in conveyor production machinery is crucial for

ensuring smooth and efficient operations in a paper recycling and box manufacturing factory.

This involves regular inspections, preventive maintenance, and timely repairs to avoid

unexpected downtime and extend the lifespan of the equipment.

 Regular Inspections: Conduct regular inspections of conveyor belts, rollers, bearings,

motors, and other critical components. Look for signs of wear, misalignment, or damage
that could lead to failures.
 Lubrication and Cleaning: Ensure that all moving parts are properly lubricated and free
of debris. Regular cleaning and lubrication reduce friction and wear, enhancing the
performance and longevity of the machinery.
 Component Replacement: Timely replacement of worn-out or damaged components,
such as belts, rollers, or bearings, prevents more severe damage and costly repairs. Keep
an inventory of essential spare parts for quick replacement.
 Alignment and Tensioning: Regularly check and adjust the alignment and tension of the
conveyor belt to ensure smooth and efficient operation. Misalignment or improper
tension can cause excessive wear and tear on the machinery.
 Monitoring Systems: Implement monitoring systems to track the performance and
condition of key components. Sensors and diagnostic tools can provide early warnings of
potential issues, allowing for proactive maintenance.

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 Maintaining key components in conveyor production machinery ensures reliable and

efficient operations, reducing downtime and extending the equipment's lifespan in a paper

recycling and box manufacturing factory.

7.1. Principles of Electric Motor Operations

Understanding the principles of electric motor operations is essential for maintaining

and troubleshooting motors used in conveyor production machinery in a paper recycling and box

manufacturing factory.

 Basic Operation: Electric motors convert electrical energy into mechanical energy

through the interaction of magnetic fields. Understanding the basic principles of

electromagnetism and how motors generate rotational force is fundamental.

 Types of Motors: Familiarize yourself with different types of electric motors used in the

factory, such as AC motors, DC motors, and servo motors. Each type has specific

applications, advantages, and maintenance requirements.

 Motor Components: Key components of an electric motor include the stator, rotor,

windings, and commutator. Knowing the function and maintenance needs of each

component helps in diagnosing and fixing issues.

 Startup and Control: Learn about motor startup procedures, control systems, and

protection mechanisms like overload relays and circuit breakers. Proper startup and

control prevent damage and ensure efficient operation.

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  Troubleshooting: Develop skills in troubleshooting common motor problems, such as

overheating, unusual noises, and loss of power. Use diagnostic tools and techniques to

identify and resolve issues quickly.

Understanding the principles of electric motor operations is crucial for maintaining

efficient and reliable motor-driven machinery in a paper recycling and box manufacturing

factory.

7.2. Incandescent Lamps and Their Connections

Incandescent lamps and their connections play a role in providing lighting for various

areas within a paper recycling and box manufacturing factory. Understanding their operation,

installation, and maintenance is important for ensuring adequate and reliable illumination.

 Basic Operation: Incandescent lamps produce light by heating a filament until it glows.

The filament is enclosed in a glass bulb filled with an inert gas to prevent oxidation.

 Electrical Connections: Proper wiring and connections are crucial for safe and efficient

operation. Ensure that lamps are connected to the correct voltage and that connections are

secure to prevent electrical hazards.

 Installation: Follow manufacturer guidelines for installing incandescent lamps. This

includes using appropriate fixtures, securing the bulb properly, and avoiding contact with

the glass to prevent damage.

 Maintenance: Regularly check and replace burnt-out lamps to ensure consistent lighting.

Clean fixtures and bulbs to maintain brightness and efficiency.

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  Energy Considerations: Be aware that incandescent lamps are less energy-efficient

compared to other lighting options like LEDs. Consider gradual replacement with more

efficient lighting to reduce energy consumption and costs.

Understanding the operation and maintenance of incandescent lamps ensures reliable

lighting and safety in a paper recycling and box manufacturing factory.

7.3. Specialized Tools for Modifying Unique Components

Using specialized tools for modifying unique components is essential for maintaining

and customizing machinery in a paper recycling and box manufacturing factory. These tools

enable precise adjustments, repairs, and enhancements to meet specific production requirements.

 Precision Measuring Tools: Tools like calipers, micrometers, and gauges are used to

measure dimensions accurately. Precise measurements ensure that components fit and

function correctly.

 Cutting and Shaping Tools: Specialized cutting tools, such as CNC machines, lathes,

and milling machines, are used to shape and modify components. These tools provide

high precision and can handle complex geometries.

 Welding and Soldering Equipment: For joining metal parts, welding and soldering

tools are essential. They provide strong and durable connections necessary for high-stress

components.

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  Fastening Tools: Tools like torque wrenches, rivet guns, and thread cutters are used to

fasten components securely. Proper fastening ensures the stability and reliability of the

machinery.

 Diagnostic and Calibration Tools: Diagnostic tools help in identifying issues, while

calibration tools ensure that components operate within specified tolerances. Regular

calibration maintains the accuracy and performance of the machinery.

Using specialized tools for modifying unique components allows for precise

customization, efficient maintenance, and enhanced performance of machinery in a paper

recycling and box manufacturing factory.

8.0. Fundamental Components of Manufacturing

Systems

Understanding the fundamental components of manufacturing systems is crucial for

optimizing production efficiency and maintaining the operational integrity of a paper recycling

and box manufacturing factory. These components include machinery, control systems, and

human resources working in harmony to achieve production goals.

 Machinery: This includes all physical equipment used in the manufacturing process,
such as conveyor belts, cutting machines, printing presses, and packaging systems.
Regular maintenance and proper operation of machinery are essential for smooth
production.
 Control Systems: Automated control systems, including PLCs (Programmable Logic
Controllers) and SCADA (Supervisory Control and Data Acquisition) systems, manage

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 and monitor machinery operations. These systems enhance efficiency, accuracy, and
safety.
 Human Resources: Skilled personnel are vital for operating machinery, performing
maintenance, and managing production processes. Continuous training and development
ensure that staff can effectively handle advanced technologies and troubleshoot issues.
 Materials and Resources: Efficient management of raw materials, energy, and other
resources is necessary to maintain production quality and reduce waste. Implementing
just-in-time inventory and resource planning systems can optimize material usage.
 Quality Control: Quality control systems and procedures ensure that the final products
meet specified standards and customer expectations. Regular inspections and testing at
various production stages help identify and correct defects.

Understanding and optimizing these fundamental components are key to maintaining

efficient and reliable manufacturing systems in a paper recycling and box manufacturing factory.

8.1. Establishing Lighting Control for Enterprises

Establishing effective lighting control in a paper recycling and box manufacturing

factory is essential for creating a safe and productive work environment. Proper lighting

enhances visibility, reduces accidents, and improves the overall efficiency of operations.

 Lighting Design: Develop a comprehensive lighting plan that addresses the specific

needs of different areas within the factory, such as production floors, storage areas, and

offices. Consider factors like illumination levels, light distribution, and energy efficiency.

 Control Systems: Implement advanced lighting control systems that allow for automated

and manual control of lighting. These systems can include timers, occupancy sensors, and

daylight harvesting technologies to optimize energy usage.

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  Energy Efficiency: Use energy-efficient lighting solutions, such as LED lights, which

consume less power and have a longer lifespan compared to traditional incandescent

lamps. This reduces energy costs and environmental impact.

 Maintenance: Regularly inspect and maintain lighting fixtures to ensure they function

correctly and provide adequate illumination. Replace burned-out bulbs and clean fixtures

to maintain brightness and efficiency.

 Safety and Compliance: Ensure that the lighting system complies with industry

standards and regulations to provide a safe working environment. Proper lighting reduces

the risk of accidents and enhances worker productivity.

Effective lighting control is crucial for maintaining a safe, efficient, and productive work

environment in a paper recycling and box manufacturing factory.

8.2. Utilizing Various Sensors for Comprehensive Equipment Protection

Utilizing various sensors for comprehensive equipment protection is essential for

ensuring the reliability and safety of machinery in a paper recycling and box manufacturing

factory. Sensors provide real-time data and alerts about the condition and performance of

equipment, enabling proactive maintenance and preventing costly failures.

 Temperature Sensors: Monitor the temperature of critical components such as motors,

bearings, and electrical panels. Overheating can indicate potential problems and lead to
equipment failure if not addressed promptly.
 Vibration Sensors: Detect abnormal vibrations in machinery, which can be an early sign
of mechanical issues like imbalance or misalignment. Early detection allows for timely
maintenance and repairs.

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  Proximity Sensors: Used to detect the presence or absence of objects, these sensors help
in automation processes and safety systems by ensuring that machinery operates only
when all conditions are met.
 Pressure Sensors: Monitor fluid and air pressure in hydraulic and pneumatic systems.
Maintaining the correct pressure levels is crucial for the proper operation of machinery.
 Load Sensors: Measure the load or weight on conveyor belts and other machinery. This
helps in preventing overloading and ensuring the machinery operates within safe limits.
 Environmental Sensors: Track environmental conditions such as humidity and dust
levels, which can affect the performance and longevity of machinery. Maintaining
optimal environmental conditions helps in protecting sensitive equipment.

Utilizing various sensors enhances equipment protection by providing critical data for

monitoring and maintenance, thus ensuring the efficient and safe operation of machinery in a

paper recycling and box manufacturing factory.

9. Monitoring of All Energy Processes

Monitoring all energy processes in a paper recycling and box manufacturing factory is

essential for optimizing energy use, reducing costs, and ensuring sustainable operations.

Effective energy monitoring helps identify inefficiencies, track energy consumption, and

implement energy-saving measures.

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  Energy Management Systems (EMS): Implement an EMS to monitor and manage

energy consumption throughout the factory. These systems provide real-time data on

energy usage, enabling better control and optimization of energy resources.

 Smart Meters and Sensors: Use smart meters and energy sensors to measure the

consumption of electricity, gas, water, and other utilities. This data helps in identifying

energy-intensive processes and areas where improvements can be made.

 Data Analysis: Analyze energy data to identify patterns, trends, and anomalies. Use this

information to develop strategies for reducing energy consumption and improving

efficiency.

 Benchmarking: Compare energy usage against industry standards and best practices to

evaluate performance. Benchmarking helps in setting realistic energy-saving targets and

measuring progress.

 Energy Audits: Conduct regular energy audits to assess the efficiency of energy

processes and identify opportunities for improvement. Audits help in pinpointing areas

where energy is wasted and recommend corrective actions.

 Employee Training and Awareness: Educate employees about the importance of

energy efficiency and how they can contribute to reducing energy consumption.

Encourage practices such as turning off equipment when not in use and using energy-

efficient devices.

 Sustainable Practices: Implement sustainable practices such as using renewable energy

sources, improving insulation, and upgrading to energy-efficient equipment. These

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 measures help in reducing the factory's carbon footprint and promoting environmental

sustainability.

Monitoring all energy processes ensures that energy resources are used efficiently and

sustainably, leading to cost savings and enhanced operational efficiency in a paper recycling and

box manufacturing factory.

10. Efficient Time Utilization During Production

Downtime

Efficiently utilizing time during production downtime is crucial for maintaining

productivity and minimizing losses in a paper recycling and box manufacturing factory.

Downtime can be planned (for maintenance and upgrades) or unplanned (due to equipment

failure), and how this time is used can significantly impact overall efficiency.

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  Preventive Maintenance: Use downtime to perform preventive maintenance on

machinery and equipment. Regular maintenance helps prevent unexpected breakdowns

and extends the lifespan of the equipment.

 Training and Development: Conduct training sessions and workshops for employees

during downtime. This is an excellent opportunity for skill enhancement and cross-

training, ensuring that staff are well-prepared for their roles.

 Process Improvements: Evaluate and improve manufacturing processes. Analyze

workflow and identify bottlenecks or inefficiencies that can be addressed to enhance

productivity.

 Equipment Upgrades: Install or upgrade machinery and technology during planned

downtime. This minimizes disruption to production and allows for smoother integration

of new equipment.

 Inventory Management: Conduct inventory audits and organize storage areas. Ensuring

that materials and supplies are well-managed can streamline production processes and

reduce waste.

 Housekeeping and Safety Checks: Perform thorough housekeeping and safety

inspections. A clean and safe working environment boosts morale and reduces the risk of

accidents.

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  Documentation and Reporting: Update and review documentation related to production

processes, maintenance logs, and safety protocols. Keeping accurate records is essential

for compliance and continuous improvement.

 Team Meetings: Hold team meetings to discuss performance, address any issues, and

plan for future projects. This promotes communication and collaboration among staff.

Efficient time utilization during production downtime enhances productivity, ensures that

machinery and processes are optimized, and prepares the factory for smooth and efficient

operations once production resumes.

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 Table 1: Cable Selection Chart

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